Weco Discovery 200 AC/DC User manual

Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
WECO srl
Via S. Antonio, 22 - BELVEDERE
36050 TEZZE SUL BRENTA (VICENZA) ITALY
Tel.[phone] - Fax [phone]
www.weco.it - E-mail [email protected]
Discovery 200 AC/DC
GB
Instruction manual

Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
Discovery 200AC/DC
2/24

Discovery 200AC/DC
Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
3/24
CONTENTS
1INTRODUCTION ............................................................................................................................................... 4
2INSTALLATION ................................................................................................................................................ 5
2.1 CONNECTIONS TO THE ELECTRICAL MAINS NETWORK ........................................................................... 5
2.2 FRONT PANEL.................................................................................................................................................. 5
2.3 REAR PANEL.................................................................................................................................................... 5
2.4 PREPARING FOR MMA WELDING.................................................................................................................. 6
2.5 PREPARING FOR TIG WELDING .................................................................................................................... 8
3COMMISSIONING........................................................................................................................................... 10
3.1 USER INTERFACE ......................................................................................................................................... 10
3.2 UNIT POWER-UP............................................................................................................................................ 12
3.3 RESET (LOAD FACTORY SETTINGS) .......................................................................................................... 12
3.4 TORCH LOADING........................................................................................................................................... 12
3.5 ALARMS MANAGEMENT ............................................................................................................................... 12
4WELDING SETTINGS..................................................................................................................................... 13
4.1 TORCH TRIGGER MODES ............................................................................................................................ 13
4.2 SELECTION OF THE WELDING MODE AND TORCH TRIGGER PROCEDURE......................................... 14
4.3 WELDING PARAMETERS .............................................................................................................................. 15
4.4 PARAMETERS ACTIVATION ......................................................................................................................... 17
4.5 PARAMETERS SETTING: (1ST LEVEL) ........................................................................................................ 18
4.6 PARAMETERS SETTING: (2ND LEVEL)........................................................................................................ 18
5TECHNICAL DATA......................................................................................................................................... 19
6SPARE PARTS ............................................................................................................................................... 20
7ELECTRICAL DIAGRAM................................................................................................................................ 22
7.1 TORCH CONNECTOR.................................................................................................................................... 23
7.2 REMOTE CONTROLLER CONNECTOR........................................................................................................ 23

Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
Discovery 200AC/DC
4/24
1INTRODUCTION
IMPORTANT!
This handbook must be consigned to the user prior to
installation and commissioning of the unit.
Read the "General prescriptions for use" handbook supplied
separately from this handbook before installing and
commissioning the unit.
The meaning of the symbols in this manual and the associated
precautionary information are given in the "General
prescriptions for use”.
If the "General prescriptions for use" are not present, it is
mandatory to request a replacement copy from the
manufacturer or from your dealer.
Retain these documents for future consultation.
KEY
DANGER!
This pictogram warns of danger of death or serious injury.
WARNING!
This pictogram warns of a risk of injury or damage to property.
CAUTION!
This pictogram warns of a potentially hazardous situation.
INFORMATION
This pictogram gives important information concerning the execution
of the relevant operations.
This symbol identifies an action that occurs automatically as a
result of a previous action.
This symbol identifies additional information or a reference to a
different section of the manual containing the associated
information.
§
This symbol identifies a reference to a chapter of the manual.
*1
The symbol refers to the associated numbered note.
NOTES
The figures in this manual are purely guideline and the images may
contain differences with respect to the actual equipment to which they
refer.
INTRODUCTION
Discovery 200 AC/DC is an advanced technology single-phase
welding power source for AC and DC TIG welding operations.
AC TIG functions are ideal for aluminum, magnesium and related
alloys welding.
AC TIG welding is optimized thanks to:
Synergic arc ignition selection located on the front panel, it modifies
the ignition according to electrode diameter.
Advanced Soft AC-Square Waveform for outstanding welding quality
through faster welding speed, better pool control and noise reduction.
Mild steel, stainless steel and copper can be easily welded in DC TIG.
Slow Pulse (0.1Hz-5.0 Hz) and Fast Pulse (5.0 Hz-250 Hz) are
available in TIG DC.
Special HF control provides100 % rapid and precise arc ignition.
Up to 3,25 mm diameter electrode welding is possible in MMA.
Accessories that can be connected to the unit:
-Overcut device to protect the power source from power supply
voltage spikes that could damage the electrical components.
-Manual remote controller for remote adjustment of the welding
current.
-Foot-pedal remote controller for TIG torch arc striking and remote
adjustment of welding current.
-Liquid cooler for TIG torches.
-Power source trolley.
Consult your dealer for an updated list of accessories and the latest
available new products.

Discovery 200AC/DC
Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
5/24
2INSTALLATION
DANGER!
Lifting and positioning
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
2.1 CONNECTIONS TO THE ELECTRICAL MAINS
NETWORK
The characteristics of the mains power supply to which the equipment
shall be connected are given in the section entitled “Technical data”
on page 19.
The machine can be connected to motorgenerators provided their
voltage is stabilised.
Connect/disconnect the various devices with the machine switched
off.
2.2 FRONT PANEL
1.
Negative pole welding socket.
2.
Connector for gas feed hose:
power source torch
3.
Connector for logic signals of TIG torch.
4.
Positive pole welding socket.
2.3 REAR PANEL
1.
Power cable.
Total length (including internal part): 2,5 m
Number and cross section of wires: 3 x 2,5 mm2
Type of plug supplied: Schuko
2.
Cooler power feeding connector.
Voltage: 230 V a.c.
Current output: 1.0 A
IP protection rating: IP20 (cap open) / IP66 (cap closed)
DANGER!
High voltage!
If the socket is not connected to any devices always close the cap:
presence of hazardous voltage levels!
3.
Connector for gas feed hose:
cylinder power source
4.
Welding power source ON/OFF switch.
1
2
4
3
1
2
3
4

Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
Discovery 200AC/DC
6/24
2.4 PREPARING FOR MMA WELDING
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Choose the electrode based on the type of material and thickness
of the workpiece to be welded.
4.
Insert the electrode in the electrode holder.
5.
Connect the electrode holder cable to the welding socket based on
the polarity requested by the type of electrode used.
6.
Connect the plug of the ground clamp to the welding socket on the
basis of the polarity required.
7.
Connect the earth clamp to the workpiece being processed.
DANGER!
Electric shock hazard!
Read the warnings highlighted by the following symbols in the
“General prescriptions for use”.
8.
Set the welding power source ON/OFF switch to “I” (unit
powered).
9.
Select the following welding mode on the user interface: MMA
10.
Set the required welding parameter values on the user interface.
When the remote controller [RC] is connected and the relative
locking screw is tightened, welding current can be adjusted using
the remote controller.
The system is ready to start welding.

Discovery 200AC/DC
Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
7/24
(polarity to basic electrode)

Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
Discovery 200AC/DC
8/24
2.5 PREPARING FOR TIG WELDING
NOTE: For the cooler to power source assembly procedure refer
to the cooler instruction manual.
1.
Set the welding power source ON/OFF switch to “O” (unit de-
energized).
2.
Plug the power cable plug into a mains socket outlet.
3.
Connect the gas hose from the welding gas cylinder to the rear
gas socket.
4.
Open the cylinder gas valve.
5.
Choose the electrode based on the type of material and
thickness of the workpiece to be welded.
6.
Insert the electrode in the TIG torch.
7.
Connect the torch plug to the welding socket on the basis of the
polarity required by the type of electrode in question.
8.
Connect the plug of the ground clamp to the welding socket on
the basis of the polarity required.
9.
Connect the gas hose from the welding torch to the front gas
socket.
10.
Couple the welding torch connector to the TIG torch signals
connector.
11.
Connect the earth clamp to the workpiece being processed.
12.
Set the welding power source ON/OFF switch to “I” (unit
powered).
13.
Select the following welding mode on the user interface: TIG DC /
TIG AC
14.
Press the torch trigger with the torch well clear of any metal parts.
This serves to open the gas solenoid valve without striking the
welding arc.
15.
Use the flow control valve to adjust the flow of gas as required
while the gas is flowing out.
16.
Set the required welding parameter values on the user interface.
When the remote control pedal is connected and the relative
locking screw is tightened the welding current will vary in relation
to the pressure exerted on the pedal.
The system is ready to start welding.

Discovery 200AC/DC
Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
9/24
(polarity for tungsten electrode)

Cod.006.0001.1340
20/02/2014 v2.11
ENGLISH
Discovery 200AC/DC
10/24
3COMMISSIONING
3.1 USER INTERFACE
CODE
SYMBOL
DESCRIPTION
L1
This LED illuminates to confirm the presence of power on the output sockets.
L2
This LED illuminates to show an anomaly in the operating conditions.
See § 3.5 ALARMS MANAGEMENT page 12.
L3
When this LED illuminates the following parameter can be set: SLOPE UP
L4
When this LED illuminates the following parameter can be set: WELDING CURRENT
L5
When this LED illuminates the following parameter can be set: SECOND CURRENT B-LEVEL
L6
When this LED illuminates the following parameter can be set: BASE CURRENT
L7
Slow pulsed DC TIG: When this LED illuminates the following parameter can be set: PEAK TIME
L8
Slow pulsed DC TIG: When this LED illuminates the following parameter can be set: BASE TIME
L7+L8
Fast pulsed DC TIG: When this LED illuminates the following parameter can be set: PULSED CURRENT FREQUENCY
L9
When this LED illuminates the following parameter can be set: DOWN SLOPE
L10
When this LED illuminates the following parameter can be set: FINAL CURRENT
L11
When this LED illuminates the following parameter can be set: POST-GAS
L12
AC TIG: When this LED illuminates the following parameter can be set: AC FREQUENCY
L13
AC TIG: When this LED illuminates the following parameter can be set: AC BALANCE
L14
AC TIG: When this LED illuminates the following parameter can be set: ELECTRODE DIAMETER